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W95900011 Revision F June, 2004 Instruction Manual plus TCU 40/80 Single Channel Temperature Control Unit BOC EDWARDS 301 Ballardvale Street Wilmington, MA 01887 Telephone: (978) 658-5410 Telex: 710-347-7672 Fax: (978) 658-7969...
TABLE OF CONTENTS SECTION TITLE PAGE PREFACE ………………………………………………………………………………………….. 1 SAFETY CONSIDERATIONS …………………………………………………………………. 1 plus TCU 40/80 …………………………………………………………………………………….. 3 SCOPE OF THE MANUAL …………………………………………………………………….. 3 plus DESCRIPTION FOR THE TCU 40/80 …………………………………………….………. 3 LOCKOUT PROCEDURE ……………………………………………………………………… 3 SAFETY FEATURES ……………………………………………………………………………4 QUICK START PROCEDURE ……………………………………………………………………. 5 POWER UP ………………………………………………………………………………….…..
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10.3.6 RS485 TCU 40/80 MESSAGE EXAMPLE ………………………………………………….. 104 APPENDIX ……………………………………………………………………………………………………105 RETURN OF BOC EDWARDS EQUIPMENT – PROCEDURE (FORM HS1) ………….…………….. 106 RETURN OF BOC EDWARDS EQUIPMENT – DECLARATION (FORM HS2) ……………………...107 LEGAL NOTICES, LIMITATIONS AND DISCLAIMERS …………………………………………….. 108 MSDS (MATERIAL SAFETY DATA SHEET) – “SUVA” HP62 ……………………………………….109...
Preface Safety Considerations Many safety features have been designed into the TCU 40/80 plus to protect the operator and the equipment. The following symbols are used in this manual to indicate the various safety conditions. General Alert General Alert symbol denotes the potential of personal hazards or equipment failure.
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Hot Surfaces symbol denotes a hazard which Hot Surfaces could cause injury or burns. Statement on avoiding the hazard. Hand Hand Protection symbol denotes a hazard which could cause injury or burns Protection Statement on avoiding the hazard. High Pressure symbol denotes a personal hazard High Pressure or equipment failure.
TCU 40/80 plus Scope of the Manual This manual provides information on the installation, start-up and operation of Edwards High Vacuum plus Model 40/80 Temperature Control Unit (TCU 40/80 The Quick Start Procedure on page 5 is a step by step guide for the start up and use of an installed, working system.
Safety Features plus The safety features listed in Table are designed into the TCU 40/80 Table 1 - Safety Features Component Ref. Des. * Function (PB1) Shuts off power to major system components. EMERGENCY button (EMO) Remote EMERGENCY (J72J2) Remote shut off of power to major system components. Drawer safety switch (LS1) Upon opening the drawer, shuts off power to major system...
Table 2 - Front Panel Indicators Quick Start Procedure Indicator Reset Start Condition Condition This Quick Start procedure is for easy start Power On Green Green up and operation of an installed and fully Reset White White working TCU 40/80 plus. If your TCU 40/80 Facility Power Green plus is not installed, go to Installation,...
4. Product Description 4.1 Refrigeration and Coolant Circuits Figure 1, Figure 2, and Table 3 on page 80 describe the refrigeration and coolant components of the TCU 40/80 plus. Figure 1- Refrigeration and Coolant Components (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
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Figure 2 - Refrigeration and Coolant Components (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...
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Table 3 - Refrigeration and Coolant Components Item Component Name Function Reservoir A holding tank for the Fluorinert coolant. Level Switch Monitors the coolant level in the reservoir. Compressor Compresses the refrigerant fluid. Crankcase Regulator Protects the compressor against pressure overload. Suction Service Valve Allows isolation at the compressor.
Coolant Circuit Coolant is pulled from the reservoir by the circulation pump and transferred to the heat exchanger where it is cooled by the refrigeration system as required. It then flows to the process equipment by means of the coolant supply hose. The coolant returns to the TCU 40/80 plus reservoir by means of the coolant return hose.
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Table 4 - Front Panel Controls Control Name Description Lights green when power is being supplied to the TCU 40/80 plus. Power On Reset Resets alarms and makes the TCU 40/80 plus ready to operate. The white light indicates that the TCU 40/80 plus is ready to operate. Removes power from all TCU 40/80 plus circuits except the EMERGENCY Emergency Off OFF circuit.
Specifications Parameter Conditions Specification Temperature Ramp Coolant Short Circuit Conditions Elapsed Time: <25 Minutes +25 °C to +80 °C Elapsed Time: <15 Minutes +25 °C to -30 °C Cooling capacity process equipment 750 Watts Process Coolant @ -40 °C 150 watt coolant line losses; coolant water @ 15 °C 2400 Watts Process Coolant @-20 °C to +80...
Dimensions 30.0 22.0 [762.0] [558.8] BOC EDWARDS 30.0 [762.0] 35.1 [892.3] plus Figure 6 - TCU 40/80 (TCU 40/80 ) Dimensions G:\Technical Documents\MANUALS\W95900011- All) CENTER OF GRAVITY SINGLE 11.10 16.86 17.02 DUAL STACKED 11.10 16.86 33.83 Figure 7 - plus...
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5.4.3 Water Connections to the water supply and return are made to either ½" brass barb fittings or ½" compression fittings. For bare hose connections (½" nominal ID): 1. Slip the hose over the barb fitting and tighten the hose clamp. 2.
5. Installation 5.1 Receiving and Unpacking Do a complete visual inspection of the TCU 40/80 plus for any damage. Do not use the TCU 40/80 plus if physical damage is evident. If there is any damage, notify your supplier and the carrier in writing within three days;...
Stacking The TCU 40/80 plus may be stacked two high. Be sure that the mounting surface can safely support the weight of the two units (920 lbs., 420 kg). Be sure that the casters of the top unit are turned inwards, but are not locked, until the top unit is fully seated.
5.4.3 Water Connections to the water supply and return are made to either ½" brass barb fittings or ½" compression fittings. For bare hose connections (½" nominal ID): Slip the hose over the barb fitting and tighten the hose clamp. Turn on the water supply and check for leaks.
Operation 6.1 Preparation Verify that water and coolant connections are made at both ends that the drain valve is closed and the coolant supply and return valves are open. Connect the remote interfaces if required. 1. To use an external RTD probe, attach it to connector J72J3. Refer to Figure 16 on page 60. Verify that the plug J72J2 is installed.
Flow Rate Adjustment Caution Do not exceed coolant pressure of 100 psi. Exceeding the coolant pressure may result in damage to the pump. The Fluorinert flow rate of the TCU 40/80 plus is factory set to provide approximately 3 gpm at 60 psig/20°C for a unit operating at 208vac/3-ph/60Hz.
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TCU 40/80 plus Temperature Control Unit...
Maintenance This section contains information that will allow you to safely keep your TCU 40/80 plus in working order. It contains important Hazard Warnings, and a Preventive Maintenance Schedule on page 28. Maintenance to the electrical Warning system of the TCU40/80 should be performed by qualified personnel only.
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The refrigerant lines are at high High pressure. Pressure Under no circumstances should the refrigerant pressure relief valve be removed or capped off. Leakage or failure of high- pressure circuits may cause injury Protection or irritation of the eyes. Eye protection should be worn when working with fluid systems.
Hazards Table 9 gives the classifications of electrical hazards. This number indicates the severity of the hazard as defined by SEMI S2-93. Table 9 - Electrical Hazards Classifications Classification Description Comment Type 1 Equipment is fully de-energized. None called out. Type 2 Equipment is energized.
Note: Uncontaminated Fluorinert may be reused. The Fluorinert should be stored in a compatible and sealed container. 7.5 Temperature Probe Calibration The BOC Edwards Temperature Controller comes equipped with a factory calibrated internal ±10V remote input/output option making calibration unnecessary. Preventive Maintenance Schedule Table 10 shows the maintenance required to keep the TCU 40/80 plus in good working order.
Semi-Annual Preventative Maintenance Refer to the Troubleshooting section 8 on page43 when results for any of the following checkpoints are not as expected. 7.7.1 Required Equipment · · 12” slotted screwdriver Spare lamps (24 vac / 60 mA) · · 4”...
7.7.8 Lamp Check/Replacement Electric Ensure all electrical power has been removed and the main Shock circuit breaker has been turned off due to the presence of high voltage or current. Should a lamp require Caution replacement, notify the appropriate personnel that an EMO condition will occur.
Annual Preventative Maintenance Refer to the Troubleshooting section 8 on page47 when results for any of the following checkpoints are not as expected. 7.8.1 Required Equipment · · 12” slotted screwdriver Miniature diagonal cutters · · 4” slotted screwdriver Halogen leak detector ·...
14. Strip the ends of all wires on base assembly and solenoid valve coils. 15. Attach wires and secure mating connections per figure 13 below. 16. Tighten the strain relief-retaining nut. 17. Install the original junction box cover and fasten attachment screw. 18.
7.8.4 System Check Component Settings Motor Overload Setting (K3) 3.5 amps Current Sensing Relay Setting (CSR) 25 amps Thermostat Setting (TS1) 210°F (Differential set at 10°F) High Pressure Switch Setting (PS1) 300 psig. (Differential set at 40 psig) Power-Up Conditions ·...
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Temperature Controller All control parameters and selections procedures for the temperature controller are accomplished through simple MENU selections. These MENU selections are organized into PAGES. On each page you will find a specific set of related functions. The PAGES setup structure is as follows: diSP PAGE, Ctrl PAGE, inPt PAGE, ScAL PAGE, Out1 PAGE and Out2 PAGE.
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EMO Circuit Do not perform the EMO circuit check while the TCU is Warning on-line with the process tool. Failure to follow these instructions will lead to the shutdown of the process tool and other associated equipment. Press the EMO button and check that the following occur. ·...
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Current Sensing Relay Set CSR1 to 50 amps. The indicator LED on CSR1 should go from green to red. After a 5 second time delay, verify that the unit shuts down, COMPRESSOR illuminates red and the alarm sounds. Press MUTE. Indicator Condition Relays...
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Water Supply Open TCU right side panel and remove PS1 cover. Using a flat head screwdriver, lift up PS1 tab. The TCU will shut down, alarm will sound, and FACILITY WATER LED should illuminate red. Press MUTE. Indicator Condition Relays CR1, CR2, CR4, CR11, CR12, CR13 On all others, Off Circuit Breakers, Coolant Temperature, Coolant...
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Coolant Flow Shut off coolant supply valve. After 5 second delay, the TCU will shut down, alarm will sound and COOLANT FLOW LED should be red. Press MUTE. Indicator Condition Relays CR1, CR4, CR7, CR11, CR12, CR13 On all others, Off Facility Water, Circuit Breakers, Coolant Temperature, Coolant Normal Level, Green Facility Power, Compressor, Coolant Low...
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Circulation Pump Adjust overload trip on K3 to the minimum setting. Within three minutes the overload will trip. After a five second time delay, the TCU will shut down, the alarm will sound and the COOLANT FLOW LED should illuminate red. Press MUTE.
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Remote Start/Stop Remove jumper from terminal strip (TB1). The TCU will shut down. Press RESET. Press START. Remote Temperature Probe Install connector J72J3 and verify REMOTE RTD illuminates green. Indicator Condition Relays CR1, CR4, CR9, CR10, CR12 On all others, Off Facility Power, Facility Water, Circuit Breakers, Compressor, Coolant Temperature, Coolant Flow, Coolant Normal Level,...
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Heating Change the temperature controller set point to 80°C. Verify contactor K4 pulls in. Verify CR15 goes out. Verify OUT 1 on the temperature controller is on and OUT 2 is off. Verify hot gas bypass solenoid (SV2) is energized. Indicator Condition Relays...
Troubleshooting Table 11, Table 12, Table 13 and Table 14 identify fault conditions that may encounter with the TCU 40/80 plus. For additional assistance contact the BOC Edwards Service Department. Table 11 - Faults Identified By Front Panel Lamps Indicator...
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Table 11 - Faults Identified By Front Panel Lamps (continued) Indicator Possible Causes Action Hazard POWER ON lamp Local EMERGENCY Verify the front panel EMERGENCY OFF Type 3 is illuminated, but OFF circuit (EMO) is (EMO) is engaged. when RESET is engaged.
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Circulation Pump: 3.5 amps per · Heater: 3 amps per leg If the current draw is in excess of the values noted above, remove power to the unit and contact a BOC Edwards service representative. TCU 40/80 plus Temperature Control Unit...
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If compressor oil is noted or a leak is located remove all power to the unit and contact a BOC Edwards service representative. Hot gas bypass solenoid Verify 24 VAC is present between wire #15 Type 4 valve (SV2) fail.
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1.4 W (± 0.3 W). Verify all three phases are within specification. If the motor winding resistance is out of tolerance contact an BOC Edwards service representative. Incorrect line voltage to Verify that the compressor is receiving all Type 4 the compressor.
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Table 12 - Faults Indicated by the Front Panel LED Indicators (continued) Indicator Possible Causes Action Hazard Flow switch may not be Monitor the voltage between wire #57 (J2-5) Type 4 set properly. and wire #58 (J3-9) located on the relay board.
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Table 13 - Faults Identified By Rear Panel Indicators Indicator Possible Causes Action Hazard Coolant NORMAL Reservoir is over-filled. Drain the reservoir until the LED turns green. LEVEL LED is Refer to “ Draining/Bleeding the Coolant amber. Reservoir” Section 7.4 page 28. Coolant LOW Fluid volume is low;...
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Moisture is in the system. Verify that the moisture indicator in the sight Type 2 glass is green. If it appears yellow in color remove power from the unit and notify a BOC Edwards service representative. TCU 40/80 Temperature Control Unit...
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If compressor oil is noted or a leak is located remove all power to the unit and contact a BOC Edwards service representative. Temperature controller Verify temperature controller PID settings. Type 2 parameters are not set to Refer to the “Temperature Controller PID...
Accessories And Spare Parts Accessories and spare parts are available from service centers at BOC Edwards companies in Brazil, Canada, Germany, Great Britain, Italy, Japan, USA, and a worldwide network of distributors. The majority of these centers employ service engineers who have undergone comprehensive BOC Edwards training courses.
10.3. RS485 Serial Communication The RS485 Interface Box Assembly was designed specifically to install only on the BOC Edwards model TCU 40/80 with RS485, BOC Edwards P.N. NW9501194. The TCU 40/80 with RS485 communications consists of two major components: TCU 40/80 with modified electrical controls drawer, External RS485 Interface Box Assembly 10.3.1 Modified Electrical Controls Drawer...
TERMINATION JUMPER SETTING: As mentioned above, the Interface Box is manufactured and shipped by BOC Edwards to the customer with the termination jumper installed. This jumper is designated “JP7” on the Microprocessor PCA, as shown in Figure 35 on page 105. Pin designation and functions for JP7 are defined in Figure 36 on page 105.
Fig 35 - RS485 Interface Box with Top Cover Removed (G:\Technical Documents\MANUALS\W95900011- All) Interface PCA Microprocessor PCA (on Microprocessor PCA) (on Interface PCA) Figure 36 - Microprocessor PCA – JP7 Pin Description and Function (G:\Technical Documents\MANUALS\W95900011- All) Enable pull-up RS-485 termination Enable 100-ohm RS-485 termination Enable pull-down RS-485 termination JP7 shows termination of the RS-485 lines enabled...
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Table 25 - TCU 40/80 “J72J1” Connector Modified for RS-485 (37-Pin D-subminiature Female) Note: Same pin designation applies to mating “P72J1” male connector PIN # ID # DESCRIPTION 5V COM I/F PCB, J2-8 +5 V I/F PCB, J2-9 +5 V Processor PCB, P2-1 +15 V I/F PCB, J2-4...
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Table 26 - Host RS-485 Communication Connector (9-Pin D-Subminiature Female) Note: Connection type is 2-wire half-duplex multi-drop RS-485 Signal Type Function TCU 40/80 Temperature Control Unit...
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10.3.4 RS485 Modicon Modbus Protocol Specification for TCU 40/80 Purpose: The purpose of this document is to define the RS485 transmission characteristics using the Modicon protocol. References: Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev J dated June 1996. RS485 Transmission Characteristics: The Modbus protocol implemented is ASCII mode (1 start bit, 7 data bits, 1 even parity bit, 1 stop bit), Longitudinal Redundancy Check (LRC), and operation at 9600 baud.
4X Memory Map: The memory-mapped registers are 16 bits in length and for purposes of discussion the least significant bit is b0 and the most significant bit is b15. The registers written to or read from are organized in a memory map. The memory map starts at location 0100 hex and runs through location 010E hex.
Appendix Return of BOC Edwards Equipment - Procedure (Form HS1) Introduction Before you return your equipment you must warn your supplier if the substances you used (and produced) in the equipment can be dangerous. You must do this to comply with health and safety at work laws.
Telephone number: __________________ Date of equipment delivery:______________________________________ I have made reasonable inquiry and I have supplied accurate information in this Declaration. I have not withheld any information. I have followed the Return of BOC Edwards Equipment Procedure (HS1) on the previous page. Signed: _______________________________________ Date: ____________________________________________...
BOC Edwards, transportation charges prepaid. In the event that BOC Edwards elects to refund the purchase price, the apparatus shall be the property of BOC Edwards and shall be shipped to BOC Edwards at BOC Edwards expense. This Mechanical Warranty shall be void and the apparatus shall be deemed to be purchased AS IS in the event that the entire purchase price has not been paid within thirty (30) days of original shipment of apparatus.
MSDS (material safety data sheet) - “SUVA” HP62 Du Pont Chemicals 6002FR Revised 15-JUL- 1993 Printed 16-DEC-1993 “SUVA” HP62” CHEMICAL PRODUCT/COMPANY IDENTIFICATION Material Identification "SUVA” is a registered trademark of DuPont. Corporate MSDS Number DUO05612 Company Identification Manufacturer/Distributor DuPont 1007 Market Street Wilmington, DE 19898 Phone Numbers Product Information...
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(Continued) Human Health Effects: Overexposure to the vapors by inhalation may include temporary nervous system depression with anesthetic effects such as dizziness, headaches, confusion, incoordination, and loss of consciousness. Higher exposures to the vapors may cause temporary alteration of the heart's electrical activity with irregular pulse, palpitations, or inadequate circulation;...
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(Continued) FIRE FIGHTING MEASURES Flammable Properties Flash Point will not burn Method Flammable limits in Air % by Volume Not applicable Not applicable Auto-ignition Not determined Fire and Explosion Hazards: Cylinders may rupture under fire conditions. Decomposition may occur. Potential Combustibility: "SUVA”...
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(Continued) HANDLING AND STORAGE Handling (Personnel) Avoid-breathing vapor. Avoid liquid contact with eyes and skin. Use with sufficient ventilation to keep employees exposure below recommended limits. Contact with chlorine or other strong oxidizing agents should also be avoided. See Fire and Explosion Data section. Storage Clean, dry area.
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(Continued) PHYSICAL AND CHEMICAL PROPERTIES Physical Data Boiling Point -46.7ºC (-52, 1ºF) Average Vapor Pressure 182.1 psig at 25°C (77°F) % Volatiles 100 WT% Evaporation Rate (CL4 = 1) Greater than 1 Solubility in Water Not determined Odor slight ethereal Form Liquefied gas Color...
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(Continued) HFC-134a Inhalation 4-hour LC50: 567,000 ppm in rats A 5 or 10 second spray of vapor produced very slight eye irritation and a 24-hour occlusive application produced slight skin irritation in rabbits. The compound is not a skin sensitizer in animals. No toxic effects were seen in animals from exposures by inhalation to concentrations up to 81,000 ppm.
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TRANSPORTATION INFORMATION Shipping Information D /IMO Proper Shipping Name LIQUEFIED GAS, N.O.S. (CONTAINS PENTAFLUORDETHANE AND TETRAFLUOROETHANE) Hazard Class UN No. 1956 DOT/IMO Label NON-FLAMMABLE GAS Shipping Containers Tank Cars, Cylinders Ton Tanks REGULATORY INFORMATION US Federal Regulations TSCA Inventory Status Reported/Included.
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BOC Edwards EUROPE AMERICAS PACIFIC UNITED KINGDOM JAPAN Edwards High Vacuum International Edwards High Vacuum International Nippon Edwards KK Manor Royal One Edwards Park Shuwa Shiba Park Building A-3F Crawley 301 Ballardvale St. 2-4-1 Shibakoen West Sussex RH10 2LW Wilmington, MA 01887...
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